HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL; 2016 - 2017 MY Prius [11/2015

Last Modified: 08-30-2021	6.10:8.0.50	Doc ID: RM100000000TBWL
Model Year Start: 2016	Model: Prius	Prod Date Range: [11/2015 - 11/2017]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL; 2016 - 2017 MY Prius [11/2015 - 11/2017]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during air conditioning unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Lane departure alert system (w/ Steering Control)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
Disconnect cable from negative auxiliary battery terminal	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)
		Intelligent clearance sonar system*1
		Simple advanced parking guidance system*1
		Pre-collision system
	Initialize back door lock	Power door lock control system
No. 1 air conditioning radiator damper servo sub-assembly No. 2 air conditioning radiator damper servo sub-assembly No. 3 air conditioning radiator damper servo sub-assembly	Initialize servo motor (Air conditioning system)	DTCs are stored

*1: When performing learning using the Techstream.

Click here

PROCEDURE

1. PRECAUTION

NOTICE:

Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.
Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the air conditioner unit assembly will not perform properly as the air conditioning amplifier assembly will not be able to recognize the position of the air conditioning radiator damper sub-assembly.

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here

5. REMOVE WATER GUARD PLATE LH

Click here

6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here

7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

8. DISCONNECT OUTLET HEATER WATER HOSE A (w/o Exhaust Heat Recirculation System)

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose A.

NOTICE:

Do not apply excessive force to the outlet heater water hose A.
Prepare a drain pan or cloth in case the coolant leaks.

9. DISCONNECT WATER PIPE AND HOSE SUB-ASSEMBLY A (w/ Exhaust Heat Recirculation System)

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the water pipe and hose sub-assembly A.

NOTICE:

Do not apply excessive force to the water pipe and hose sub-assembly A.
Prepare a drain pan or cloth in case the coolant leaks.

10. DISCONNECT INLET HEATER WATER HOSE A

(a) w/o Exhaust Heat Recirculation System:

(1) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose A.

NOTICE:

Do not apply excessive force to the inlet heater water hose A.
Prepare a drain pan or cloth in case the coolant leaks.

(b) w/ Exhaust Heat Recirculation System:

(1) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose A.

NOTICE:

Do not apply excessive force to the inlet heater water hose A.
Prepare a drain pan or cloth in case the coolant leaks.

11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Remove the bolt and rotate the hook connector as shown in the illustration.

(b) Disconnect the suction pipe sub-assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

12. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

(a) Disconnect the air conditioner tube and accessory assembly.

(b) Remove the O-ring from the air conditioner tube and accessory assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

13. REMOVE FRONT SEAT ASSEMBLY LH

for Manual seat:

Click here

for Power seat:

Click here

14. REMOVE FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

Click here

15. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

Click here

16. REMOVE STEERING COLUMN ASSEMBLY

Click here

17. REMOVE SKID CONTROL BUZZER (w/ Toyota Safety Sense P)

Click here

18. REMOVE DRIVING SUPPORT ECU ASSEMBLY (w/ Toyota Safety Sense P)

Click here

19. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

Click here

20. REMOVE NO. 1 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System)

Click here

21. REMOVE NO. 2 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System)

Click here

22. REMOVE CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System)

Click here

23. REMOVE BACK-UP BATTERY WITH BRACKET (w/ Manual (SOS) Switch)

Click here

24. REMOVE ECU INTEGRATION BOX RH

Click here

25. REMOVE SHIFT LOCK CONTROL UNIT ASSEMBLY

Click here

26. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR

(a) Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.

27. REMOVE FRONT NO. 1 CONSOLE BOX INSERT

(a) Disengage the clip and claw as shown in the illustration.

	Place Hand Here
	Remove in this Direction

(b) Disengage the guide to remove the front No. 1 console box insert as shown in the illustration.

Remove in this Direction

28. REMOVE FRONT NO. 2 CONSOLE BOX INSERT

(a) Disengage the clip and claw as shown in the illustration.

	Place Hand Here
	Remove in this Direction

(b) Disengage the guide to remove the front No. 2 console box insert as shown in the illustration.

Remove in this Direction

29. REMOVE FRONT FLOOR CAUTION PLATE COVER

(a) Disengage the claw and guide as shown by the arrow (1), and then pull the front floor caution plate cover as shown by the arrow (2) in the illustration to remove it.

	Place Hand Here
	Remove in this Direction (1)
	Remove in this Direction (2)

HINT:

When replacing a type A front floor carpet assembly with a type B front floor carpet assembly, it is not necessary to remove the front floor caution plate cover.

for Type A

for Type B

30. REMOVE REAR NO. 3 AIR DUCT

(a) Remove the 2 front floor carpet clips.

(b) Disengage the 2 guides and turn back the front floor carpet assembly as shown in the illustration.

Remove in this Direction

31. REMOVE REAR NO. 2 AIR DUCT

(a) Disengage the 2 claws and remove the rear No. 2 air duct.

32. REMOVE REAR NO. 5 AIR DUCT

(a) Remove the 2 front floor carpet clips.

(b) Disengage the 2 guides and turn back the front floor carpet assembly as shown in the illustration.

Remove in this Direction

33. REMOVE REAR NO. 4 AIR DUCT

(a) Disengage the 2 claws and remove the rear No. 4 air duct.

34. REMOVE REAR NO. 1 AIR DUCT

(a) Disengage the 4 claws to remove the rear No. 1 air duct.

35. REMOVE NO. 3 DASH PANEL INSULATOR PAD

(a) Cut each claw of the 2 clips and remove the No. 3 dash panel insulator pad.

NOTICE:

If the No. 3 dash panel insulator pad is damaged, replace it with a new one.

Cut

(b) Remove the 2 clips.

36. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Turn back the front floor mat as shown in the illustration.

(b) Disengage each clamp.

(d) Remove the bolt, screw, nut and No. 1 instrument panel brace sub-assembly.

	Bolt
	Screw
	Nut

37. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Turn back the front floor mat as shown in the illustration.

(b) Disengage each clamp.

	Bolt
	Screw
	Nut

38. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

(a) Disengage the clamp and 2 claws to disconnect the DLC3 connector.

	Bolt
	Nut

(b) Remove the bolt, nut and No. 3 instrument panel to cowl brace sub-assembly.

39. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

Click here

40. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Disengage the 6 claws to remove the lower defroster nozzle assembly.

41. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:

Be sure to support the air conditioner unit assembly when removing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
When disassembling the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

(a) Disconnect each connector.

*a	Earth Wire	*b	Relay Block Assembly
	Connector		Bolt

(b) Remove the 3 bolts and disconnect the 3 earth wires.

(d) Disengage each clamp and disconnect the instrument panel wire.

(e) Disconnect the drain cooler hose.

NOTICE:

If the cooler unit drain hose grommet is disconnected from the vehicle body while disconnecting the drain cooler hose, make sure to replace it with a new one. Failure to do so may cause water ingress.

*1	COOLER UNIT DRAIN HOSE GROMMET

(f) Remove the 2 bolts.

(g) Remove the 4 bolts (A).

	Bolt (A)		Bolt (B)
	Nut	-	-

(h) Remove the bolt (B) and disconnect the parking brake pedal assembly.

(i) Remove the nut.

(j) Disconnect each connector.

Remove in this Direction

(k) Remove the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

(l) Disengage the claw and 2 guides and disconnect the ID code box (immobiliser code ECU) as shown in the illustration.

Remove in this Direction

42. REMOVE AIR CONDITIONER UNIT ASSEMBLY

(a) Remove the 3 bolts and air conditioner unit assembly from the instrument panel reinforcement assembly.